A wireless sensor monitoring network and monitoring method for underground monorail crane

Abstract

The present invention discloses a wireless sensor monitoring network for underground monorail cranes, including a coordinator aggregation node, a data display processing device, and a plurality of brake block monitoring nodes, a tie rod stress monitoring node, a carriage vibration monitoring node, and a routing relay node; wherein the brake block monitoring node, the tie rod stress monitoring node, and the carriage vibration monitoring node are respectively connected to the routing relay node through a universal communication control module, the routing relay node is connected to the coordinator aggregation node through a universal communication control module, and the coordinator aggregation node is connected to the data display processing device through a universal communication control module. The present invention arranges nodes at various locations of the locomotive body to monitor the braking, vibration, and tie rod status of the monorail crane, make up for the monitoring loopholes of the electrical control system, and uploads the node monitoring data and the locomotive electrical control system data to the locomotive control room through the mine tunnel wireless communication base station, so as to realize real-time monitoring of the operation status of the monorail crane.

Description

Technical Field

[0001] The invention relates to the field of wireless sensor monitoring networks, and in particular to an underground monorail crane wireless sensor monitoring network and a monitoring method thereof. Background Art

[0002] The degree of modernization of auxiliary transportation mechanization is the key to measuring whether coal mines can achieve efficient production. Traditional auxiliary transportation methods include overhead line electric locomotives, battery locomotives, winches, etc. They are often very complex and have many transportation links, and the transportation efficiency is low. Monorail crane locomotives make up for the shortcomings of overhead line electric locomotives and battery locomotives that do not have the ability to climb grades. It not only improves transportation efficiency, but also reduces labor costs and reduces the occurrence of transportation accidents. Due to the above many advantages, monorail crane locomotives have gradually been used in major coal mines.

[0003] At present, the monitoring system of the monorail crane is mainly set up in the front part of the locomotive to monitor the operating status of the front equipment. It is an important part of the locomotive electronic control system. When the monorail crane's own electrical and hydraulic equipment failures affect the stable operation of the locomotive, most of the problems can be discovered and solved through the electronic control system. However, the current monitoring of monorail crane locomotives is limited to the electronic control instruments in the locomotive cab, and there is a lack of monitoring of the locomotive's mechanical structure. The mechanical part of the locomotive currently relies on manual regular inspections and maintenance. The Inoue locomotive monitoring room's control of the locomotive is limited to the location information of the positioning system. The driver needs to actively report and feedback when an accident occurs. The existing monitoring is fragmented and lacks systematic real-time active monitoring. Summary of the invention

[0004] Purpose of the invention: In view of the above problems, the purpose of the present invention is to provide an underground monorail crane wireless sensor monitoring network and a monitoring method thereof, to establish a monorail crane operation status monitoring system, to arrange nodes at various locations on the locomotive body, to monitor the braking, vibration, and pull rod status of the monorail crane, to make up for the monitoring loopholes of the electrical control system, and to upload the node monitoring data and the locomotive electronic control system data to the locomotive control room through the mine tunnel wireless communication base station, to realize real-time monitoring of the monorail crane operation status, and according to the linear layout characteristics of the monitoring nodes, to use a non-uniform deployment strategy to balance the energy consumption of routing nodes, to extend the network life, and to ensure the safe and efficient operation of the entire transportation system.

[0005] Technical solution: One aspect of the present invention provides an underground monorail crane wireless sensor monitoring network, including a coordinator aggregation node, a data display processing device, and a plurality of brake block monitoring nodes, a tie rod stress monitoring node, a carriage vibration monitoring node, and a routing relay node;

[0006] The brake block monitoring node, the rod stress monitoring node, and the carriage vibration monitoring node are respectively connected to the routing relay node through the universal communication control module, the routing relay node is connected to the coordinator aggregation node through the universal communication control module, and the coordinator aggregation node is connected to the data display and processing device through the universal communication control module;

[0007] The brake block monitoring nodes are distributed and installed on the monorail crane braking device to collect the wear and temperature data of the brake block;

[0008] The tie rod stress monitoring node is installed on the monorail suspension tie rod to monitor the tie rod stress condition in real time;

[0009] The carriage vibration monitoring node is installed on the monorail crane carriage to monitor the three-axis vibration acceleration and three-axis roll angle of the carriage in real time;

[0010] The routing relay node is installed on the body of the monorail crane locomotive to collect and forward the data of the nodes in the cluster;

[0011] The coordinator aggregation node is installed in the monorail crane cab and is used to collect all node data and locomotive electronic control parameters in the monitoring network;

[0012] The data display and processing equipment is set up in the mine tunnel locomotive dispatching room, and receives all node data and locomotive electronic control parameters through the mine Ethernet ring network.

[0013] Further, the brake block monitoring node includes a brake sensor FPC board, a brake information processing module, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a brake information processing module housing;

[0014] The brake sensor FPC board is connected to the brake information processing module, the brake information processing module is connected to the communication control module, the communication control module is powered by the universal power supply module, the brake information processing module is installed in the brake information processing module housing, the communication control module is installed in the universal node housing, the universal power supply module is installed in the universal power supply housing, and the universal node housing, the universal power supply housing and the brake information processing module housing are adsorbed on the monorail crane body.

[0015] Further, the tie rod stress monitoring node includes a stress information processing module, a full-bridge strain gauge, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a stress information processing module housing;

[0016] The full-bridge strain gauge is connected to the stress information processing module, the stress information processing module is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the full-bridge strain gauge is pasted on the horizontal direction of the outer end surface of the monorail crane pull rod earring, the stress information processing module is installed in the stress information processing module shell, the universal communication control module is installed in the universal node shell, the universal power supply module is installed in the universal power supply shell, and the universal node shell, the universal power supply shell and the stress information processing module shell are adsorbed on the monorail crane body.

[0017] Further, the carriage vibration monitoring node includes a universal communication control module, an acceleration sensor, a universal power supply module, a universal node housing and a universal power supply housing;

[0018] The acceleration sensor is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the universal communication control module is installed in the universal node shell, and the universal power supply module is installed in the universal power supply shell, and the universal node shell and the universal power supply shell are adsorbed on the monorail crane.

[0019] Further, the data display and processing device includes a data display storage module and a data analysis and processing module, wherein the data display storage module includes a TCP communication module, a data storage module, a data sending module, a data receiving module, a data display module, an alarm module and a display storage data transmission module; the data analysis and processing module includes an analysis and processing data transmission module, a mathematical model data processing module and a deep learning data processing module;

[0020] The data display and storage module receives data and sends data to the coordinator aggregation node through the TCP communication module, the data storage module stores the received data, the data sending module issues instructions to the monitoring node through the TCP communication module, the data receiving module displays the received raw data frames, the data display module classifies and processes the received data frames, displays the actual monitoring parameters and the analysis results of the display data analysis and processing module, and the display storage data transmission module transmits data to the data analysis and processing module;

[0021] The data analysis and processing module analyzes and processes the received data, imports the mathematical model data processing module and the deep learning data processing module. The mathematical model data processing module calculates the Sperling index of the locomotive operation stability based on the vibration signals of each carriage of the monorail crane in the complex frequency domain. The deep learning data processing module uses the locomotive braking, pull rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to judge the operating status of the monorail crane, including the locomotive health status, operating status and track status, and feeds back to the data display and storage module through the analysis and processing data transmission module.

[0022] Furthermore, the brake sensor FPC board includes copper wire cables, a temperature sensor and an FPC connector. The spacing between the copper wire cables is determined according to the required brake monitoring accuracy, the number of copper wire cables is determined by the thickness of the wear area of ​​the brake block, and the inner circle of the brake sensor FPC board fits the outer edge of the friction end face of the brake block; the temperature sensor is installed in the non-wear area of ​​the brake block of the brake sensor FPC board, in a horizontal position in the forward direction of the brake block side surface, to monitor the maximum temperature of the brake block side surface.

[0023] Furthermore, the braking information processing module includes a voltage-dividing chip resistor and multiple parallel chip resistors. Each parallel chip resistor is connected to a circuit of copper wire wiring to form multiple parallel loops. The general communication control module collects the total voltage and temperature sensor data of the parallel resistor circuit and uploads it. The data display processing equipment determines the amount of wear based on the collected voltage value.

[0024] Furthermore, the full-bridge strain gauge is pasted in the horizontal direction of the outer end face of the pull rod earring. It is the maximum normal stress component of the outer end face of the pull rod earring obtained by finite element analysis. After amplification and filtering by the stress information processing module, the full-bridge strain gauge outputs a voltage signal between 0-3.3V. The general communication control module collects the voltage signal and uploads it.

[0025] Furthermore, routing relay nodes are deployed on the monorail crane in a non-uniform spacing manner, and each routing relay node collects and uploads the monitoring sensor node data.

[0026] Another aspect of the present invention provides an underground monorail crane wireless sensor monitoring method, comprising the following steps:

[0027] Step 1, using the coordinator aggregation node to create a wireless sensor network;

[0028] Step 2: Use the brake monitoring node to collect brake block wear and temperature data, use the tie rod stress monitoring node to collect the horizontal normal stress of the outer end surface of the tie rod earring, and use the car vibration monitoring node to collect the three-axis vibration acceleration and three-axis roll angle of the car;

[0029] Step 3: Use the routing relay node to collect nearby monitoring node data and upload it to the routing relay node;

[0030] Step 4: Use the coordinator aggregation node to collect Zigbee data from all nodes and collect sensor data from the monorail crane electric control system through the USB interface, and upload it to the WIFI base station installed at intervals on the wall of the mine tunnel through WIFI. The WIFI base station is connected to the mine Ethernet ring network;

[0031] Step 5: The data display processing device receives the monitoring network data through the mine Ethernet ring network, including:

[0032] The data display and storage module classifies and locates the data frames of multiple brake block temperatures, wear, rod stress, car vibration acceleration, roll angle, and electronic control system sensors collected by the node, displays and stores them in real time, and issues alarms based on pre-set thresholds;

[0033] The mathematical model data processing module of the data analysis and processing module evaluates the locomotive running stability according to the Sperling index in the complex frequency domain of vibration acceleration and the roll angle; the deep learning data processing module of the data analysis and processing module judges the running status of the locomotive, extracts features according to the temperature and wear of each brake block, the stress data of each tie rod, the three-axis acceleration of each car vibration, the three-axis roll angle data and the sensor data of the locomotive electronic control system, and corresponds to the running status of the monorail crane;

[0034] The deep learning data processing module analyzes the structural abnormalities of the monorail crane track based on stress and vibration data, and makes track status judgments and early warnings for track misalignment. At the same time, based on the monitoring network data and the sensor data parameters of the monorail crane's electronic control system, it extracts features of common operating faults of the monorail crane, and judges and issues early warnings on the health status of the monorail crane based on the monitoring parameters.

[0035] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages:

[0036] The present invention is easy to install and maintain, safe and reliable, and has a low cost. It will not cause damage to the monorail crane locomotive and will not affect the normal operation of the monorail crane. The node power supply adopts rechargeable lithium batteries, which are reusable and environmentally friendly. The present invention improves the loopholes of the monorail crane's electronic control monitoring system, and performs supplementary monitoring on the brakes, pull rods, and vibrations that are not easy to monitor in the hydraulic electronic control system. The present invention uses FPC wiring to detect the wear of the monorail crane's brake blocks. The detection method is novel, less sensitive to environmental factors, and reliable. The detection accuracy can be changed according to the spacing between copper wire conductors, and the thickness and temperature of the brake blocks can be monitored in real time even when the monorail crane is running. The present invention monitors the stress of the pull rod, which is the main bearing component of the running power of each section of the monorail crane. It is proposed to monitor the normal stress in the horizontal direction of the outer end face of the pull rod earring, which is a special point of the pull rod stress distribution and the stress size can effectively reflect the wear changes of the earring. The present invention monitors the vibration of the monorail crane car body. Vibration is an important evaluation index of rail transportation equipment. It is proposed to make up for the monitoring loopholes of the car body from the aspects of three-axis vibration acceleration and three-axis roll angle. The communication control system adopts Zigbee chip as the core processor, which can accurately realize data collection and sensor network data transmission, and is easy to network. The number of monitoring nodes can be increased according to the length and structure of the monorail crane. The coordinator aggregation node of the present invention adopts WIFI module to upload data, and uploads it to the locomotive monitoring room in real time according to the wireless communication base station installed in the mine tunnel, without adding additional base station equipment. The data display storage program of the present invention receives sensor network data frames from TCP, judges the data frame category and the actual node position, and the user can observe in real time. The data display is intuitive and clear, there is a threshold alarm, and the historical data storage is retained; the present invention monitors the overall drawbar stress and car vibration of the monorail crane locomotive in real time, and can achieve real-time monitoring and alarm for major transportation accidents that may occur during operation, such as falling off the track, running away, collision, etc.; the present invention can analyze and judge various operating states, health states, and track states of the monorail crane, and calculate the Sperling index of the locomotive operation evaluation with the car vibration acceleration to judge its operating stability. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 It is an overall schematic diagram of the present invention;

[0038] Figure 2 This is a structural principle diagram of the coordinator aggregation node of the present invention;

[0039] Figure 3 It is a structural diagram of the universal node housing of the present invention;

[0040] Figure 4 This is a schematic diagram of the contact structure between the brake block and the track of the present invention;

[0041] Figure 5 This is a schematic diagram of the brake monitoring node PCB of the present invention;

[0042] Figure 6 This is a structural diagram of the brake information processing module housing of the present invention;

[0043] Figure 7 This is a structural diagram of a universal power supply housing of the present invention;

[0044] Figure 8 This is a schematic diagram of the installation of the brake sensor module of the present invention;

[0045] Fig. 9 This is a schematic diagram of the PCB of the tie rod stress monitoring node of the present invention;

[0046] Fig.10 This is a structural diagram of the housing of the tie rod stress information processing module of the present invention;

[0047] Fig.11 This is a schematic diagram of the installation of the pull rod and the full-bridge strain gauge of the present invention;

[0048] Fig.12 This is a schematic diagram of a car vibration monitoring node of the present invention;

[0049] Fig.13 This is a finite element analysis diagram of the contact temperature between the brake block and the track of the present invention;

[0050] Fig.14 This is a finite element analysis diagram of the contact wear between the brake block and the track of the present invention;

[0051] Fig.15 This is a finite element analysis diagram of the pull rod earring stress of the present invention;

[0052] Fig.16 It is the work flow chart of the present invention.

[0053] In the figure: 1. Monorail crane track; 2. Monorail crane cab; 3. Coordinator aggregation node; 4. Monorail crane pull rod; 5. Pull rod stress monitoring node; 6. Monorail crane brake device; 7. Braking monitoring node; 8. Monorail crane carriage; 9. Carriage vibration monitoring node; 10. Routing relay node; 11. Data transmission and processing equipment; 12. General communication control module; 13. Reset module; 14. WIFI interface; 15. Braking monitoring interface; 16. Stress monitoring interface; 17. Voltage conversion module; 18. Power supply interface; 19. Power switch; 20. USB interface; 21. Serial communication module; 22. Vibration monitoring interface; 23. JTAG interface; 24. Zigbee chip; 2 5. Universal node housing; 26. Brake block; 27. Brake information processing module; 28. Brake information processing connector; 29. ​​Parallel chip resistor; 30. Brake information processing FPC connector; 31. Brake sensor FPC board; 32. Temperature sensor; 33. FPC copper wire cable; 34. Brake sensor FPC connector; 35. Brake information processing module housing; 36. Universal power supply housing; 37. Full-bridge strain gauge; 38. Monorail suspension rod; 39. Monorail suspension rod earrings; 40. Strain information processing module; 41. Stress information processing connector; 42. Low-pass filter module; 43. Full-bridge strain gauge connector; 44. Voltage amplification module; 45. Stress information processing module housing. DETAILED DESCRIPTION

[0054] In order to make the objectives, technical solutions and advantages of the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0055] Embodiment 1

[0056] like Figure 1 The figure shows a schematic diagram of the structure of a wireless sensor monitoring network for underground monorail cranes according to the present embodiment, including a coordinator aggregation node 3, a data display processing device 11, and a plurality of brake block monitoring nodes 7, a tie rod stress monitoring node 5, a carriage vibration monitoring node 9 and a routing relay node 10;

[0057] The brake block monitoring node, the rod stress monitoring node, and the carriage vibration monitoring node are respectively connected to the routing relay node through the universal communication control module, the routing relay node is connected to the coordinator aggregation node through the universal communication control module, and the coordinator aggregation node is connected to the data display and processing device through the universal communication control module;

[0058] The brake block monitoring nodes are distributed and installed on the monorail crane braking device to collect the wear and temperature data of the brake block;

[0059] The tie rod stress monitoring node is installed on the monorail suspension tie rod to monitor the tie rod stress condition in real time;

[0060] The carriage vibration monitoring node is installed on the monorail crane carriage to monitor the three-axis vibration acceleration and three-axis roll angle of the carriage in real time;

[0061] The routing relay node is installed on the body of the monorail crane locomotive to collect and forward the data of the nodes in the cluster;

[0062] The coordinator aggregation node is installed in the monorail crane cab and is used to collect all node data and locomotive electronic control parameters in the monitoring network;

[0063] The data display and processing equipment is set up in the mine tunnel locomotive dispatching room, and receives all node data and locomotive electronic control parameters through the mine Ethernet ring network.

[0064] like Figure 2 As shown, the coordinator aggregation node 3 includes a general communication control module 12, a WIFI module, and a general node housing 25. The general communication control module 12 includes a Zigbee chip 24, a voltage conversion module 17, a serial communication module 21, a reset module 13, a JTAG interface 23, a USB interface 20, a power switch 19, a power interface 18, a stress monitoring interface 16, a braking monitoring interface 15, a WIFI interface 14, and a vibration monitoring interface 22. The voltage conversion module 17 includes a 5V voltage conversion chip and a 3.3V voltage conversion chip. The serial communication module 21 includes a serial port to USB chip and a chip resistor. The reset module 13 includes a touch switch, a chip resistor, and a chip capacitor. The WIFI interface 14 is connected to the WIFI module, and the power interface 18 is connected to a 7.4V lithium battery. The general communication control module 12 and the WIFI module are installed in the general node housing 25. The structural schematic diagram of the general node housing 25 is shown in FIG. Figure 3 As shown, the universal node housing 25 is adsorbed in the monorail crane cab 2 by a magnet, and the universal communication control module USB interface 20 connects the sensor data of the monorail crane electronic control system and provides power.

[0065] The brake block monitoring node includes a brake sensor FPC board, a brake information processing module, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a brake information processing module housing;

[0066] The brake sensor FPC board is connected to the brake information processing module, the brake information processing module is connected to the communication control module, the communication control module is powered by the universal power supply module, the brake information processing module is installed in the brake information processing module housing, the communication control module is installed in the universal node housing, the universal power supply module is installed in the universal power supply housing, and the universal node housing, the universal power supply housing and the brake information processing module housing are adsorbed on the monorail crane body.

[0067] In one example, the monorail lock block and the track are in flat contact friction braking, such as Figure 4 As shown. Figure 5 As shown, the brake block monitoring node 7 includes a brake sensor FPC board 31, a brake information processing module 27, a universal communication control module 12, a universal power supply module, a universal node housing 25, a universal power supply housing 36 and a brake information processing module housing 35, wherein the brake information processing module housing 35 is as shown in FIG. Figure 6 As shown, the universal power supply housing is as follows Figure 7 As shown. Figure 8 As shown, the brake sensor FPC board 31 is pasted on the side surface of the monorail crane brake block 26. The brake sensor FPC board 31 includes a temperature sensor 32, multiple FPC copper wire cables 33 and a brake sensor FPC connector 34. The temperature sensor 32 is installed on the edge of the brake sensor FPC board 31 and installed on the non-wear area of ​​the side surface edge of the brake block 27 in the horizontal direction of movement. The brake sensor FPC connector 34 is connected to the brake information processing module 27. Each copper wire conductor 34 of the FPC cable is respectively connected to each parallel chip resistor 29 of the brake information processing module 27. The FPC cable 34 is pasted on the wear area of ​​the side surface of the brake block 27. The brake information processing module 27 includes a brake information processing FPC connector 30, a brake information processing connector 28 and multiple parallel chip resistors 29. The brake information processing connector 28 is connected to the brake monitoring interface 15 of the general communication control module 12. The general communication control module 12 is connected to a 7.4V lithium battery through the power interface 18. The braking information processing module 27 is installed in the braking information processing module housing 35, the universal communication control module 12 is installed in the universal node housing 25, and the universal power supply module is installed in the universal power supply housing 36. Magnets are installed at the bottom of the universal node housing 25, the universal power supply housing 36, and the braking information processing module housing 35. The universal node housing 25 and the braking information processing module housing 35 are adsorbed on the monorail crane braking device 6 by magnets.

[0068] Furthermore, the spacing between the copper wires is determined according to the required braking monitoring accuracy, the number of copper wires is determined by the thickness of the wear area of ​​the brake block, and the inner circle of the brake sensor FPC board fits the outer edge of the friction end face of the brake block; the temperature sensor is installed in the non-wear area of ​​the brake block on the brake sensor FPC board, in a horizontal position in the forward direction of the brake block side surface, to monitor the maximum temperature of the brake block side surface.

[0069] Furthermore, the braking information processing module includes a voltage-dividing chip resistor and multiple parallel chip resistors. Each parallel chip resistor is connected to a circuit of copper wire wiring to form multiple parallel loops. The general communication control module collects the total voltage and temperature sensor data of the parallel resistor circuit and uploads it. The data display processing equipment determines the amount of wear based on the collected voltage value.

[0070] The tie rod stress monitoring node includes a stress information processing module, a full-bridge strain gauge, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a stress information processing module housing;

[0071] The full-bridge strain gauge is connected to the stress information processing module, the stress information processing module is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the full-bridge strain gauge is pasted on the horizontal direction of the outer end surface of the monorail crane pull rod earring, the stress information processing module is installed in the stress information processing module shell, the universal communication control module is installed in the universal node shell, the universal power supply module is installed in the universal power supply shell, and the universal node shell, the universal power supply shell and the stress information processing module shell are adsorbed on the monorail crane body.

[0072] In one example, if Fig. 9 As shown, the rod stress monitoring node 5 includes a stress information processing module 40 and a full-bridge strain gauge 37, a universal communication control module 12, a universal power supply module, a universal node housing 25, a universal power supply housing 36 and a stress information processing module housing 45. The stress information processing module housing is shown in FIG. Fig.10 As shown. The stress information processing module 40 includes a stress information processing connector 41, a full-bridge strain gauge connector 43, a voltage amplification module 44 and a low-pass filter module 42. The full-bridge strain gauge 37 is attached to the horizontal direction of the outer end of the monorail suspension rod ring 39 and connected to the full-bridge strain gauge connector 43 of the stress information processing module 40. The stress information processing connector 41 is connected to the stress monitoring interface 16 of the universal communication control module 12. The universal communication control module 12 is connected to the universal power module 7.4V lithium battery through the power interface 18. The universal communication control module 12 is installed in the universal node housing 25, the universal power module is installed in the universal power housing 26, and the stress information processing module 40 is installed in the stress information processing module housing 45. Magnets are installed at the bottom of the universal node housing 25, the universal power housing 36 and the stress information processing module housing 45, and are adsorbed on the monorail locomotive rod 4 by magnets.

[0073] Further, the installation position of the full-bridge strain gauge 37 is as follows Fig.11 As shown, the full-bridge strain gauge is pasted on the horizontal direction of the outer end face of the tie rod earring. It is the maximum normal stress component of the outer end face of the tie rod earring obtained by finite element analysis. After amplification and filtering by the stress information processing module, the full-bridge strain gauge outputs a voltage signal between 0-3.3V. The general communication control module collects the voltage signal and uploads it.

[0074] The carriage vibration monitoring node includes a universal communication control module, an acceleration sensor, a universal power supply module, a universal node housing and a universal power supply housing;

[0075] The acceleration sensor is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the universal communication control module is installed in the universal node shell, and the universal power supply module is installed in the universal power supply shell, and the universal node shell and the universal power supply shell are adsorbed on the monorail crane.

[0076] In one example, if Fig.12 As shown, the carriage vibration monitoring node 9 includes a universal communication control module 12, an acceleration sensor, a universal power module, a universal node housing 25 and a universal power housing 36. The acceleration sensor is connected to the universal communication control module 12 through the vibration monitoring interface 22, and the universal power module 7.4V lithium battery is connected to the universal communication control module 12 through the power interface 18. The universal communication control module 12 is installed in the universal node housing 25, and the universal power module is installed in the universal power housing 36. Magnets are installed at the bottom of the universal node housing 25 and the universal power housing 36, and are adsorbed on the monorail locomotive carriage 8 by magnets.

[0077] The routing relay node 10 includes a universal communication control module 12, a universal power module, a universal node housing 25 and a universal power housing 36. The routing relay node 10 is installed in the universal node housing 25, and the universal power module is installed in the universal power housing 36. The universal node housing 10 and the universal power housing 36 are attached to the monorail crane body by magnets. The routing relay nodes 10 are deployed on the monorail crane body in a non-uniform spacing manner, and each of the routing relay nodes collects and uploads the monitoring sensor node data.

[0078] The data display and processing device includes a data display storage module and a data analysis and processing module, wherein the data display storage module includes a TCP communication module, a data storage module, a data sending module, a data receiving module, a data display module, an alarm module and a display storage data transmission module; the data analysis and processing module includes an analysis and processing data transmission module, a mathematical model data processing module and a deep learning data processing module;

[0079] The data display and storage module receives data and sends data to the coordinator aggregation node through the TCP communication module, the data storage module stores the received data, the data sending module issues instructions to the monitoring node through the TCP communication module, the data receiving module displays the received raw data frames, the data display module classifies and processes the received data frames, displays the actual monitoring parameters and the analysis results of the display data analysis and processing module, and the display storage data transmission module transmits data to the data analysis and processing module;

[0080] The data analysis and processing module analyzes and processes the received data, imports the mathematical model data processing module and the deep learning data processing module. The mathematical model data processing module calculates the Sperling index of the locomotive operation stability based on the vibration signals of each carriage of the monorail crane in the complex frequency domain. The deep learning data processing module uses the locomotive braking, pull rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to judge the operating status of the monorail crane, including the locomotive health status, operating status and track status, and feeds back to the data display and storage module through the analysis and processing data transmission module.

[0081] In one example, the data display processing device 11 includes a host computer data display storage module and a data analysis processing module. The data display storage module is developed by Labview, including a TCP communication module, a data storage module, a data sending module, a data receiving module, a data display module, an alarm module, and a display storage data transmission module; the data analysis processing module is developed by Python, including an analysis and processing data transmission module, a mathematical model data processing module, and a deep learning data processing module. The data display and storage module receives data and sends data to the coordinator aggregation node through the TCP communication module, the data storage module stores the received data, the data sending module issues instructions to the monitoring node through the TCP communication module, the data receiving module displays the received original data frame, the data display module classifies and processes the received data frame, displays the actual monitoring parameters and the analysis results of the display data analysis and processing module, and the display storage data transmission module transmits the data to the data analysis and processing module; the data analysis and processing module analyzes and processes the received data, and imports the mathematical model data processing module and the deep learning data processing module respectively. The mathematical model data processing module calculates the Sperling index of the locomotive operation stability in the complex frequency domain for the vibration signals of each carriage of the monorail crane. The deep learning data processing module uses the locomotive braking, pull rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to judge the status of the monorail crane, such as the locomotive health status, operation status, and track status, and feeds back to the data display and storage module through the analysis and processing data transmission module.

[0082] The working principle of the underground monorail crane wireless sensor monitoring network is:

[0083] A Zigbee network is established using the coordinator aggregation node 3, which is connected to the lane WIFI base station. The routing relay node 10 joins the Zigbee network. The brake monitoring node 7, the tie rod stress monitoring node 5, and the car vibration monitoring node 9 are connected to the nearest routing relay node 10 to join the Zigbee network. The monitoring node collects data and uploads it to the routing relay node 10. The routing relay node 10 receives the sub-node data and uploads it. The coordinator node 3 receives the node data and the electronic control system parameters and uploads them to the lane base station through WIFI. The data display and processing device 11 receives the data. The data display module distinguishes the data frames and determines the actual location of the data, displays the data in a chart form and records it, and displays the results of the data analysis and processing module. The data analysis and processing module calculates the Sperling operation stability index based on the acceleration complex frequency domain of the monitoring data, and judges the locomotive operation status, health status, and track status according to the monitoring data and the electronic control system parameters according to the neural network.

[0084] The monitoring network of the present invention is easy to install and maintain, safe and reliable, low in cost, does not cause damage to the monorail crane locomotive, does not affect the normal operation of the monorail crane, and adopts rechargeable lithium batteries for node power supply, which can be reused and environmentally friendly; the loopholes of the existing monorail crane electronic control monitoring system are improved, and the brake, pull rod, and vibration that are not easy to monitor in the hydraulic electronic control system are supplemented with monitoring; the wear amount of the monorail crane brake block is detected by using FPC wiring. Compared with the traditional manual detection of the brake block, the detection method of the present invention is novel, less sensitive to environmental factors, reliable, and the detection accuracy can be changed according to the spacing of the copper wire conductors. Even when the monorail crane is running, the thickness and temperature of the brake block can be monitored in real time. The present invention monitors the stress of the pull rod, which is the main bearing component of the running power of each section of the monorail crane body. It is proposed to monitor the normal stress in the horizontal direction of the outer end face of the pull rod earring, which is a special point of the pull rod stress distribution and the stress size can effectively reflect the wear change of the earring. The present invention monitors the vibration of the monorail crane car, which is an important evaluation index of rail transportation equipment, and proposes to make up for the monitoring loopholes of the car body from the aspects of three-axis vibration acceleration and three-axis roll angle. The communication control system of the present invention adopts Zigbee chip as the core processor, which can accurately realize data collection and sensor network data transmission, and is convenient for networking. The number of monitoring nodes can be increased according to the length and structure of the monorail crane. The coordinator aggregation node of the present invention adopts WIFI module to upload data, and uploads it to the locomotive monitoring room in real time according to the wireless communication base station installed in the mine tunnel, without adding additional base station equipment. The data display storage program of the present invention receives the sensor network data frame from TCP, judges the data frame category and the actual node position, and the user can observe in real time. The data display is intuitive and clear, there is a threshold alarm, and the historical data is retained. The present invention monitors the overall rod stress and carriage vibration of the monorail crane locomotive in real time, and can achieve real-time monitoring and alarm for major transportation accidents that may occur during operation, such as falling off the road, running away, collision, etc. The present invention uses a deep learning neural network to train the characteristic data such as monorail crane braking, rod, carriage vibration, and electronic control system parameters, and can analyze and judge various operating states and structural problems of the monorail crane, and calculates the Sperling index of the locomotive operation evaluation with the carriage vibration acceleration to judge its operating stability.

[0085] Embodiment 2

[0086] The underground monorail crane wireless sensor monitoring method described in this embodiment is applied to the underground monorail crane wireless sensor monitoring network constructed in Example 1. The monitoring method specifically includes the following steps:

[0087] Step 1, using the coordinator aggregation node to create a wireless sensor network;

[0088] Step 2: Use the brake monitoring node to collect brake block wear and temperature data, use the tie rod stress monitoring node to collect the horizontal normal stress of the outer end surface of the tie rod earring, and use the car vibration monitoring node to collect the three-axis vibration acceleration and three-axis roll angle of the car;

[0089] Step 3: Use the routing relay node to collect nearby monitoring node data and upload it to the routing relay node;

[0090] Step 4: Use the coordinator aggregation node to collect Zigbee data from all nodes and collect sensor data from the monorail crane electric control system through the USB interface, and upload it to the WIFI base station installed at intervals on the wall of the mine tunnel through WIFI. The WIFI base station is connected to the mine Ethernet ring network;

[0091] Step 5: The data display processing device receives the monitoring network data through the mine Ethernet ring network, including:

[0092] The data display and storage module classifies and locates the data frames of multiple brake block temperatures, wear, rod stress, car vibration acceleration, roll angle, and electronic control system sensors collected by the node, displays and stores them in real time, and issues alarms based on pre-set thresholds;

[0093] The mathematical model data processing module of the data analysis and processing module evaluates the locomotive running stability according to the Sperling index in the complex frequency domain of vibration acceleration and the roll angle; the deep learning data processing module of the data analysis and processing module judges the running status of the locomotive, extracts features according to the temperature and wear of each brake block, the stress data of each tie rod, the three-axis acceleration of each car vibration, the three-axis roll angle data and the sensor data of the locomotive electronic control system, and corresponds to the running status of the monorail crane;

[0094] The deep learning data processing module analyzes the structural abnormalities of the monorail crane track based on stress and vibration data, and makes track status judgments and early warnings for track misalignment. At the same time, based on the monitoring network data and the sensor data parameters of the monorail crane's electronic control system, it extracts features of common operating faults of the monorail crane, and judges and issues early warnings on the health status of the monorail crane based on the monitoring parameters.

[0095] like Fig.16 As shown, the implementation process of the underground monorail crane wireless sensor monitoring method is as follows:

[0096] (1) The monorail crane coordinator aggregation node 3 is installed in the monorail crane cab 2 to create a wireless sensor network. The Zigbee communication collects the data of each node and the parameters of the locomotive electronic control system and uploads them to the tunnel WIFI base station through the WIFI module via the serial port communication. The WIFI base station is connected to the mine tunnel Ethernet ring network and finally uploaded to the data display processing equipment 11 located in the locomotive monitoring and dispatching room through TCP communication. The monorail crane brake monitoring node 7, the tie rod stress monitoring node 5, and the car vibration monitoring node 9 are correspondingly installed on all the brake devices 6, tie rods 4, and cars 8 of the monorail crane in a linear deployment state. The monorail crane routing relay node 10 is installed on the monorail crane body in an uneven deployment. The routing relay nodes 10 close to the coordinator aggregation node 3 have a short spacing, and the routing relay nodes 10 far away from the coordinator aggregation node 3 have a long spacing.

[0097] (2) The braking motion of the brake block 26 on the monorail track 1 is subjected to a dynamics-thermo-rigid coupling finite element analysis. The results are as follows: Fig.13 As shown in the figure, the temperature distribution of the friction end surface of the brake block 27 and the track 1 is that the temperature at the center of the brake block is the highest, followed by the horizontal direction of the brake block, and the temperature of the end surface of the brake block 27 in the direction perpendicular to the running direction of the brake block 27 is the lowest. In order to measure the highest temperature of the end surface of the brake block 27 as much as possible, the temperature sensor 32 of the brake sensor FPC board 31 is installed on the side surface of the brake block 27 in the horizontal direction of the brake block 27. The temperature sensor 32 communicates with the general communication control module 12 through a single bus. The transient structural wear finite element analysis of the braking movement of the brake block 26 on the monorail hanging track 1 is performed, and the results are shown in the figure. Fig.14 As shown, the friction end face of the brake block 27 and the track 1 wears more in the forward direction. In order to measure the maximum wear of the end face of the brake block 27, the inner circle of the wear monitoring FPC board 32 is designed with parallel and evenly distributed FPC copper wire cables 33. When the end face of the brake block 27 is worn, the innermost wire of the FPC copper wire cable 33 is worn and disconnected, and the parallel chip resistor 29 circuit of the corresponding brake information processing module 27 is disconnected, and the parallel resistor 30 circuit disconnects a parallel circuit. The total voltage of all parallel resistors 30 collected by the general communication control module 12 changes, and the collected voltage value and temperature pass through the routing relay node 10 via Zigbee communication. Finally, the data display processing device 11 compares the obtained voltage value with the corresponding wear amount to obtain the wear amount of the brake block 27 in real time.

[0098] (3) Through the finite element analysis of the static structure of the monorail suspension rod 38, the rod 38 bears the tension at both ends, such as Fig.15As shown, the maximum equivalent stress is located at the tie rod earring 39, wherein the normal stress in the horizontal direction is the main component of the equivalent stress on the outer end face of the tie rod earring 39. When the tie rod earring 39 and the tie rod are worn at the fish mouth, the normal stress on the outer end face of the tie rod earring 39 will also change significantly. The normal stress in the horizontal direction of the outer end face of the tie rod earring 39 is measured by the full-bridge strain gauge 37, and the voltage value is finally collected by the general communication control module 12 through the stress information processing module 40, the voltage amplification module 44 and the low-pass filter module 42. The data display processing device 11 can observe the stress changes of the tie rod 38 in real time and issue a timely warning.

[0099] (4) The monorail crane car vibration monitoring node 9 collects the three-axis acceleration and three-axis roll angle of the monorail crane car body in real time through the six-axis motion processing sensor via IIC communication, and converges them to the coordinator aggregation node 3 through the routing relay node 10.

[0100] (5) The data display and processing device 11 includes a data display storage module and a data analysis and processing module. The data display storage module receives data and sends data to the coordinator aggregation node 3 through the TCP communication module, the data storage module stores the received data, the data sending module issues instructions to the monitoring node through the TCP communication module, the data receiving module displays the received raw data frame, the data display module classifies and processes the received data frame, displays the actual monitoring parameters and the analysis results of the display data analysis and processing module, and the display storage data transmission module transmits the data to the data analysis and processing module; the data analysis and processing module analyzes and processes the received data, and imports the mathematical model data processing module and the deep learning data processing module respectively. The mathematical model data processing module calculates the locomotive operation stability Sperling index of the vibration signal of each carriage of the monorail crane in the complex frequency domain, and the deep learning data processing module extracts features of various states of the monorail crane based on the locomotive braking, tie rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input, such as locomotive health status, operation status, and track status. Through the locomotive electronic control parameters such as engine speed, oil temperature and oil pressure, hydraulic system hydraulic pressure and other parameters, and the parameters collected by the sensor monitoring nodes, characteristic information is extracted for early warning of common health problems of the monorail crane such as engine status and leakage. The operating status of the monorail crane such as flat and inclined lane braking, uphill and downhill, acceleration and deceleration, and curve driving are monitored through the three-axis acceleration and tie rod stress parameters. The running track status such as anchor rod descent and track error is analyzed through vibration signals, and the data is fed back to the data display and storage module through the analysis and processing data transmission module.

Claims

1. An underground monorail crane wireless sensor monitoring network, characterized in that: It includes a coordinator aggregation node, a data display and processing device, and multiple brake block monitoring nodes, a tie rod stress monitoring node, a carriage vibration monitoring node, and a routing relay node; The brake block monitoring node, the rod stress monitoring node, and the carriage vibration monitoring node are respectively connected to the routing relay node through the universal communication control module, the routing relay node is connected to the coordinator aggregation node through the universal communication control module, and the coordinator aggregation node is connected to the data display and processing device through the universal communication control module; The brake block monitoring nodes are distributed and installed on the monorail crane braking device to collect the wear and temperature data of the brake block; The tie rod stress monitoring node is installed on the monorail suspension tie rod to monitor the tie rod stress condition in real time; The carriage vibration monitoring node is installed on the monorail crane carriage to monitor the three-axis vibration acceleration and three-axis roll angle of the carriage in real time; The routing relay node is installed on the body of the monorail crane locomotive to collect and forward the data of the nodes in the cluster; The coordinator aggregation node is installed in the monorail crane cab and is used to collect all node data and locomotive electronic control parameters in the monitoring network; The data display and processing equipment is set up in the mine tunnel locomotive dispatching room, and receives all node data and locomotive electronic control parameters through the mine Ethernet ring network; The brake block monitoring node includes a brake sensor FPC board, a brake information processing module, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a brake information processing module housing; The brake sensor FPC board is connected to the brake information processing module, the brake information processing module is connected to the communication control module, the communication control module is powered by the universal power supply module, the brake information processing module is installed in the brake information processing module housing, the communication control module is installed in the universal node housing, the universal power supply module is installed in the universal power supply housing, and the universal node housing, the universal power supply housing and the brake information processing module housing are adsorbed on the monorail crane body; The tie rod stress monitoring node includes a stress information processing module, a full-bridge strain gauge, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a stress information processing module housing; The full-bridge strain gauge is connected to the stress information processing module, the stress information processing module is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the full-bridge strain gauge is pasted on the horizontal direction of the outer end surface of the monorail suspension rod earring, the stress information processing module is installed in the stress information processing module housing, the universal communication control module is installed in the universal node housing, the universal power supply module is installed in the universal power supply housing, and the universal node housing, the universal power supply housing and the stress information processing module housing are adsorbed on the monorail crane body; The carriage vibration monitoring node includes a universal communication control module, an acceleration sensor, a universal power supply module, a universal node housing and a universal power supply housing; The acceleration sensor is connected to a universal communication control module, and the universal communication control module is powered by a universal power supply module; the universal communication control module is installed in a universal node housing, the universal power supply module is installed in a universal power supply housing, and the universal node housing and the universal power supply housing are adsorbed on the monorail crane; The data display and processing device includes a data display storage module and a data analysis and processing module, wherein the data display storage module includes a TCP communication module, a data storage module, a data sending module, a data receiving module, a data display module, an alarm module and a display storage data transmission module; the data analysis and processing module includes an analysis and processing data transmission module, a mathematical model data processing module and a deep learning data processing module; The data display and storage module receives data and sends data to the coordinator aggregation node through the TCP communication module, the data storage module stores the received data, the data sending module issues instructions to the monitoring node through the TCP communication module, the data receiving module displays the received raw data frames, the data display module classifies and processes the received data frames, displays the actual monitoring parameters and the analysis results of the display data analysis and processing module, and the display storage data transmission module transmits data to the data analysis and processing module; The data analysis and processing module analyzes and processes the received data, and imports the mathematical model data processing module and the deep learning data processing module. The mathematical model data processing module calculates the Sperling index of the locomotive operation stability in the complex frequency domain for the vibration signals of each carriage of the monorail crane. The deep learning data processing module uses the locomotive braking, rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to judge the operation status of the monorail crane, including the locomotive health status, operation status and track status, and feeds back to the data display and storage module through the analysis and processing data transmission module; The brake sensor FPC board includes copper wire cables, temperature sensors and FPC connectors. The spacing of the copper wire cables is determined according to the required brake monitoring accuracy, and the number of copper wire cables is determined by the thickness of the wear area of ​​the brake block. The inner circle of the brake sensor FPC board fits the outer edge of the friction end face of the brake block. The temperature sensor is installed in the non-wear area of ​​the brake block on the brake sensor FPC board, at a horizontal position on the side surface of the brake block in the forward direction, to monitor the maximum temperature of the side surface of the brake block. The brake information processing module includes a voltage-dividing chip resistor and multiple parallel chip resistors. Each parallel chip resistor is connected to a circuit of copper wire wiring to form multiple parallel loops. The general communication control module collects the total voltage and temperature sensor data of the parallel resistor circuit and uploads it. The data display processing equipment determines the amount of wear based on the collected voltage value.

2. The underground monorail crane wireless sensor monitoring network according to claim 1 is characterized in that: The full-bridge strain gauge is pasted on the outer end face of the tie rod earring in the horizontal direction. It is the maximum normal stress component of the outer end face of the tie rod earring obtained by finite element analysis. After amplification and filtering by the stress information processing module, the full-bridge strain gauge outputs a voltage signal between 0-3.3V. The general communication control module collects the voltage signal and uploads it.

3. The underground monorail crane wireless sensor monitoring network according to claim 1 is characterized in that: The routing relay nodes are deployed on the monorail crane in a non-uniform spacing manner. Each routing relay node collects and uploads the data of the monitoring sensor nodes.

4. A method for monitoring a wireless sensor for an underground monorail crane, applied to the wireless sensor monitoring network for an underground monorail crane as claimed in any one of claims 1 to 3, characterized in that: The following steps are involved: Step 1, using the coordinator aggregation node to create a wireless sensor network; Step 2: Use the brake monitoring node to collect brake block wear and temperature data, use the tie rod stress monitoring node to collect the horizontal normal stress of the outer end surface of the tie rod earring, and use the car vibration monitoring node to collect the three-axis vibration acceleration and three-axis roll angle of the car; Step 3: Use the routing relay node to collect nearby monitoring node data and upload it to the routing relay node; Step 4: Use the coordinator aggregation node to collect Zigbee data from all nodes and collect sensor data from the monorail crane electric control system through the USB interface, and upload it to the WIFI base station installed at intervals on the wall of the mine tunnel through WIFI. The WIFI base station is connected to the mine Ethernet ring network; Step 5: The data display processing device receives the monitoring network data through the mine Ethernet ring network, including: The data display and storage module classifies and locates the data frames of multiple brake block temperatures, wear, rod stress, car vibration acceleration, roll angle, and electronic control system sensors collected by the node, displays and stores them in real time, and issues alarms based on pre-set thresholds; The mathematical model data processing module of the data analysis and processing module evaluates the locomotive running stability according to the Sperling index in the complex frequency domain of vibration acceleration and the roll angle; the deep learning data processing module of the data analysis and processing module judges the running status of the locomotive, extracts features according to the temperature and wear of each brake block, the stress data of each tie rod, the three-axis acceleration of each car vibration, the three-axis roll angle data and the sensor data of the locomotive electronic control system, and corresponds to the running status of the monorail crane; The deep learning data processing module analyzes the structural abnormalities of the monorail crane track based on stress and vibration data, and makes track status judgments and early warnings for track misalignment. At the same time, based on the monitoring network data and the sensor data parameters of the monorail crane's electronic control system, it extracts features of common operating faults of the monorail crane, and judges and issues early warnings on the health status of the monorail crane based on the monitoring parameters.

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